Process of corrugating pulpboard



June 17, 1924.

D. M. SUTHERLAND. JR

PROCESS OF CORRUGATING PULPBOARD Filed Feb. 25 1920 3 Sheets-Sheet 1 F U I 1 I l l I I l I I I l I I I |||||||I||||.| .llllllllrllnllI WITNESSES June 17, 1924. 1,497,809

D. M. SUTHERLAND. JR v PROCESS OF CORRUGATING PULPBOARD le Feb 25. 1920 :s Sheets-Sheet 2 AM W WWFM A TTORNE Y 8 June 17 1924.

D. M. SUTHERLAND. JR

PROCESS OF CORRUGATING PULPBOARD Filed Feb 25 1920 3 Sheets-Sheet 5 WITNESSES i B! F ATTORNEYS Patented June 1 7, i924.

umrso STATES PATENT OFFICE.

DANIEL is. surnnnnnm), m, or rnnn'ron, NEW Jnnsmr, ASSIGNOR 'ro TEE sensors mom 00,, or nwme rownsm, mzw means, A conrom'rion or nnw rnocnss or oonnues'rnm .runrnosnn.

Application filed February 25, 1920. Serial No. 381,280.

To all whom it my concern:

Be it known that I, DANIEL M. Sumn- LAND, J12, a subject of the King of Great.

Britain, and a resident of Trenton, county of Mercer, State of hha w J erseyphave invented certain new and useful iIinpi ovemeuts in a. Process of CorrugatingPulpboard, of which the following is a specification.

I The (present invention relates to a' process of mol ing pul board. I

The principa ob ect of the invention is to As gradual molding the bending -ronshaping 65 provide an improved process of making corrugated pulp board from relatively thick,

. stock (for example three eighths'of an inch) containing a large admixture, say 35% or a more, of gltchy material as for example, mineral pitc like substance. The process, however, is not asphalt, resinous compounds of restricted to the formation. of corrugated.

sheets, since any desired attern may impressed upon. the materia treated, as will be obvious to those skilled theart. p

' Pulp vboard isvusually made by running paper pulp, wood puip',-gor" the like into a mold, removingthe ma ority of the water by means of pressure;iand"subsequentl' drying v, out theremainder of the water by-t e] application of heat. The board after substanv tially all the water removed, is in what I term a spongy "condition and is then H p g Fig. 3 is a left side view ofthe same;

Fig. 4 is a vertical sectional view taken 85" through the center-of Fig. 1; the showin itc y material incorporated therein as a" inder. By the. term pitchy material I mean to include bituminous, remnous' and similar materials which have the property of'becomin'g soft and pliable when suitably heated.

-' The process oft she present invention in volves she; ing' the compaetedboard while hot. The ard may bemolded ately after it is comlplzztlzltelxll and l'gile still;-

as coo ma i r Shawn a r0118 indicated by hot, or ulp board w rehea The principle of the invention will be best understoodfrom-a description of a fiarticus lar application of the process and a tionib an apparatus suitable, for use nectigin' with the invention.

Filii'flle yrposevof illustration! 6 articularly described 1 molding means consists f operates' the forming dies.

H board, that is'to say, a corrugated pulp board containing 35% or more by weight of pitch,

asphalt, or similar material; Y

'l lo make corrugated pitch board by my improved process, the 'com acted ulp sheet while in thoroughly heate condition so that the itch or other binderis soft, is bent or.

mol ed gradually to form the desired corruT i} gations. The temperature of the heatedboard may be for example 300 F. or higher. a convenient manner oi providing a may be performed in successive steps, each step brillgl'ing the board more nearly to the v desired ape. The bending or- -s hapin is preferably done under such conditions t at heat is continually applied to maintain the heated, and therefore softened condition of the P p b ard. The action of the-mate i l during molding is not thoroughly under -fl stood. n is believed the .binderacts as lubricant when iii, heated condition and thusf 'm facilitates the movement of the fibres relative being somewhat exaggerated as to the di ference in diameters of the several rolls.

Fig. 5 is a detail view ofzon'e of the fluted rollsshowing the manner of same. I a v The apparatus shown for the purposes of illustration comprises heating 'means and molding means. The heating means is shown as a pair of flat heated dies 5,6. The

of a plurality of molding dies or pattern dies which are e'n meralsi'r to 1% inclusive; Preferably also farmingdi'es 13, 14 are provided to nsure the accu- 10c rate finished Shape of the" material. Suitablegearing drives the pattern rolls and The heating dies5, 6 may conveniently be the compacting dies which heat and compact the pulp board from the spongy condiheating the so "pacted by the pattern rolls.

tion. In fact the process may be considered as comprising the step of compacting the pulp board to substantially its finished condition before bending or molding as distinguished from a process in which thethick pulp board is simultaneously bent and com- The pattern rolls are shownas intermeshing fluted rolls arranged to mold or bend the pulp board to form corrugated board.

To mold corrugated board in accordance with the present invention and with the'apparatus illustrated a length of the material is heated between the dies 5, 6 and when hot is fed as by the feed rolls 15, 16 to the fluted trolls which gradually mold or bend the board in successive steps to the desired form.

If the pulp board has not been compacted previously, the dies 5, fishould be arranged to compact as well as to heat the material.

By way of example three pairs of rolls are shown. The rolls 7, 8 of the first pair are provided with shallow intermeshing corrugations which giverelatively slight bends alternately in opposite directions to the pulp board as it passes therebetween. The rolls till 9, 1010f the second pair are more deeply fluted and are arranged to engage and increase the bends formed by the first rolls. The rolls 11, 12 of the third pair are still more deeply fluted and give substantially the final form to the pulp board. If an accurate shaping of the finished article is desired it is further treated between the heated forming dies 13, it which are of a shape corresponding to the finished form desired. The diameters of the rolls of the several sets must he such as to feed the proper length of material.

'lhe rolls are preferably driven at a slow speed so that the molding will be accomlished gradually in the sense that each endin operation will be performed slowly as well as in the sense that the molding operation as a whole is accomplished gr du ally by extending the operation as a w ole over a period of time.

Suitable gearing for operating the pattern rolls, the feed rolls and the forming dies alternately in suitably timed relation is conventionally illustrated.v As the gearing is arranged, the forming dies are moved to ward and from each other and caused to dwell in each extreme position. The dwell of the dies in closed relation causes the application of heat and pressure to be continued for a short interval of time. The dwell in open relation permits operation of the pattern rolls and feeding of the material.

terrupted gears-l8, 19 the first meshin with an in tepted gear 20 fast upon t e eccentric shaft 21, which operates the lower forming die 14, the second meshing with an interrupted gear 22, securedto the shaft 23 of the pattern roll 12. As clearly illustrated in Fig. 2, all the pattern rolls and the feed rolls are connected by suitable gears to cause the same to travel at one uniform peripheral velocity so. that each time the interrupted gear 22 is driven, all the pattern rolls and the feed rolls will be simultaneously driven in the desired direction. By uniform peripheral velocity I mean that for each of the rollers, the length of material fed at one operation (one-sixth of a revolution for the pattern rolls, in this particular example), isthe same as -for the other rollers The upper eccentric shaft 241, operating the upper forming die 13, is connected to rotate simultaneously with the lower eccentric shaft 21, so that the dies are simultanously moved toward and from each other.

As shown a vertical shaft 25 (Fig. 3) is connected to both eccentric shafts by miter ing concave locking sections of the gear 20 to cause dwells in the movement of the forming dies while in both open and closed positions. The gear 19 has only one tooth section 33 the remainder of the ear bein smooth. The toothed section 33 1s arrange to engage any of the corresponding toothed sections 34 of the gear 22 to drive said gear and through it and the connected gearing to drive all of the fluted rolls one sixth of a revolution. The smooth portion is arranged to engage the concave locking portions 35 or the car 22 to cause a dwell in the movement 0 the gear. 22 and oil" all the pattern rolls. The gears 18 and 19 are so arranged that the gear 22 through which the pattern rolls are operated is driven only while the supply steam to the forming dies 13, 14. The pattern rolls are shown as hollow and as provided with hollow shafts 37 arranged to admit steam to the rolls as conventionally shown in Fig. 5.

The foregoing description is illustrative only and variation in both the process and apparatus will readily occur to one skilled in the art.

I claim: v

1. The process of molding pulp board having a pitchybinder incorporated there-,

in which comprises compacting the board, and then molding the same in successive stages while heating it each subs uent stage. bringing the article closer to its a1 shape than the preceding stage.

2. The process of molding pulp board having a pitchy binder incorporated therein whlch comprises compacting the board, and then molding the same with gradually applied pressure while heating it such pressure being applied in successive steps during each of which the material is heated, each subsequent step bringing the material closer to the final shape than the preceding steps.

3. The process of molding previously compacted pulp board having a pitchy binder incorporated therein which comprises heating the pulp board until the binder is softened and then simultaneously heating and molding the pulp board in a succession of steps bringing it progressively to the desired shape.

4. The process of molding previously compacted pulp board having a pitchy binder incorporated therein which comrises heating the pulp board until the binder is softened and then simultaneously heating, feeding and molding the pulp board in a succession of steps bringing it progresively to the desired shape.

5. The process of molding previously comdpacted pulp board having a pitchy bin prises heating thepulp board until the binder is softened, then heating the pulp board and simultaneously feeding it while molding corrugations therein in a succession of steps which increase the depth of the corrugations progresively, and there-- upon compressing the corru ated ul board thus obtained, while holding it sta tionary.

6. The process of molding pulp board comprising pitchy material which comprises heating the pulp board and then molding it in successive stages or steps which bring the said pulp board progressively nearer the desired molded shape with continued application of heat during the successive moldin ste s.

T e process of molding pulp board having a pitchy binder incorporated therein whlch comprises first heating and com pacting the ulp board and then molding the same wit gradually applied pressure, said pressure being applied in a series of steps, each subsequent step bringing the material closer to its final shape than the preceding steps.

DANIEL M. SUTHERLAND, JR.

er incorporated therein which com-. 

